6-speed manual gearbox 02S

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 2 Identification
  2
• 2.1 Gearbox identification
  2
• 3 Repair instructions
  4
• 3.1 General repair instructions
  4
• 4 Technical data
  9
• 4.1 Allocation gearbox - engine
  9
• 4.2 Capacities
  9
• 4.3 Calculation of gear ratios
  10
• 5 Overview - power transmission
  11
• 5.1 Overview - power transmission - front-wheel drive
  11
• 6 Electrical components
  13
• 6.1 Overview of fitting locations - electrical components
  13
• Clutch
  15
• 1 Clutch mechanism
  15
• 1.1 Assembly overview - pedal cluster
  15
• 1.2 Assembly overview - clutch hydraulics
  17
• 1.3 Assembly overview - clutch release mechanism
  20
• 1.4 Removing and installing clutch pedal
  22
• 1.5 Removing and installing over-centre spring
  27
• 1.6 Removing and installing mounting bracket
  31
• 1.7 Removing and installing clutch master cylinder
  39
• 1.8 Removing and installing clutch slave cylinder
  42
• 1.9 Removing and installing lines for clutch mechanism
  46
• 1.10 Bleeding clutch mechanism
  48
• 1.11 Checking clutch master cylinder and clutch slave cylinder
  50
• 1.12 Removing and installing clutch position sender G476
  50
• 1.13 Repairing clutch release mechanism
  52
• 2 Clutch
  54
• 2.1 Assembly overview - clutch
  54
• 2.2 Removing and installing clutch
  54
• Controls, housing
  60
• 1 Selector mechanism
  60
• 1.1 Installation position - selector mechanism
  60
• 1.2 Assembly overview - selector mechanism
  61
• 1.3 Assembly overview – gear knob and cover
  62
• 1.4 Assembly overview - Gear lever and selector housing
  63
• 1.5 Assembly overview – selector cables
  65
• 1.6 Removing and installing gear knob
  67
• 1.7 Removing and installing selector mechanism
  69
• 1.8 Dismantling and assembling selector mechanism
  79
• 1.9 Removing and installing gear selector cable
  85
• 1.10 Adjusting selector mechanism
  88
• 1.11 Checking selector mechanism
  91
• 1.12 Renewing selector shaft seal
  91
• 2 Removing and installing gearbox
  94
• 2.1 Specified torques for gearbox
  94
• 2.2 Removing gearbox
  94
• 2.3 Installing gearbox
  104
• 3 Assembly mountings
  113
• 3.1 Assembly overview - assembly mountings
  113
• 4 Transporting gearbox
  117
• 5 Dismantling and assembling gearbox
  119
• 5.1 Schematic overview - gearbox
  119
• 5.2 Assembly overview - gearbox
  120
• 5.3 Assembly overview - cover for gearbox housing and 5th/6th gear
  121
• 5.4 Assembly overview - gearbox housing and selector mechanism
  124
• 5.5 Assembly overview - selector unit
  126
• 5.6 Assembly overview - input shaft, output shafts, differential, selector rods
  126
• 5.7 Assembly overview - selector forks
  128
• 5.8 Repairing selector unit
  131
• 5.9 Repairing selector forks
  133
• 5.10 Removing cover for gearbox housing and 5th and 6th gears
  138
• 5.11 Dismantling and assembling gearbox
  145
• 5.12 Installing cover for gearbox housing and 5th and 6th gears
  163
• 6 Gearbox housing, clutch housing
  171
• 6.1 Assembly overview - gearbox housing and clutch housing
  171
• 6.2 Assembly overview - gearbox housing cover
  173
• 6.3 Repairing gearbox housing
  174
• 6.4 Repairing clutch housing
  176
• 6.5 Repairing gearbox housing cover
  177
• 7 Securing to engine and gearbox support
  181
• 8 Gear oil
  183
• 8.1 Checking gear oil level
  183
• 8.2 Draining and filling gear oil
  183
• Gears, shafts
  187
• 1 Input shaft
  187
• 1.1 Assembly overview - input shaft
  187
• 1.2 Dismantling and assembling input shaft
  189
• 1.3 Adjusting input shaft
  196
• 1.4 Renewing input shaft seal
  200
• 2 Output shaft
  203
• 2.1 Assembly overview - output shaft
  203
• 2.2 Dismantling and assembling output shaft
  206
• 2.3 Adjusting output shaft
  220
• 3 Reverse shaft
  225
• 3.1 Assembly overview - reverse shaft
  225
• 3.2 Dismantling and assembling reverse shaft
  227
• Final drive - differential
  231
• 1 Oil seals
  231
• 1.1 Overview of fitting locations - seals
  231
• 1.2 Renewing left seal
  231
• 1.3 Renewing right seal
  234
• 2 Differential
  239
• 2.1 Assembly overview - differential
  239
• 2.2 Dismantling and assembling differential
  241
• 2.3 Adjusting differential
  249
• 3 Adjustment overview
  253